KTM 65 SX 1999 Owner'S Manual Download

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OWNER'S MANUAL

2016

65 SX

Art. no. 3213328en

Summary of Contents for 65 SX 1999

Page 1: ...OWNER S MANUAL 2016 65 SX Art no 3213328en...

Page 2: ......

Page 3: ...materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice...

Page 4: ...absorber 24 10 9 Adjusting the spring preload of the shock absorber 25 10 10 Adjusting the riding sag 25 10 11 Checking the basic setting of the fork 26 10 12 Adjusting the compression damping of the...

Page 5: ...eel 59 13 4 Installing the rear wheel 59 13 5 Checking the tire condition 60 13 6 Checking tire air pressure 60 13 7 Checking spoke tension 61 14 COOLING SYSTEM 62 14 1 Cooling system 62 14 2 Checking...

Page 6: ...here your motorcycle will be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page Indicate...

Page 7: ...at will lead to environmental damage if the appropriate measures are not taken 2 4 Tampering warning Tampering with the noise control system is prohibited Federal law prohibits the following acts or t...

Page 8: ...is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them for damage and wear Change damaged or worn parts After you com...

Page 9: ...PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the se...

Page 10: ...ew of vehicle front left example H00040 10 1 Hand brake lever p 11 2 Rebound damping of fork 3 Clutch lever p 11 4 Quick release for seat lock 5 Shock absorber rebound adjustment 6 Shift lever p 13 7...

Page 11: ...ght example H00041 10 1 Filler cap 2 Kill switch p 11 3 Compression damping of fork 4 Throttle grip p 11 5 Chassis number p 10 6 Kick starter p 13 7 Foot brake lever p 13 8 Shock absorber compression...

Page 12: ...e steering head 5 2 Engine number 401949 10 The engine number is located on the left side of the engine under the engine sprocket 5 3 Shock absorber part number 0 0 1 1 401948 10 The shock absorber pa...

Page 13: ...the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is...

Page 14: ...d lift it free 6 6 Closing the filler cap H00147 10 Replace the filler cap and turn clockwise until the release button locks in place Info Run the fuel tank breather hose without kinks 6 7 Fuel tap H0...

Page 15: ...ight side of the engine The kick starter can be swiveled Info Before riding swing the kick starter inwards towards the engine 6 11 Foot brake lever 401956 10 Foot brake lever is located in front of th...

Page 16: ...ing Danger of accidents Critical riding behavior due to inappropriate riding Ensure that your child adapts the riding speed to the road conditions and to his or her riding abilities Warning Danger of...

Page 17: ...ible and in a standing position to get a better feeling for the vehicle Do not let your child ride on terrain that exceed your child s capabilities and experience Your child should hold the handlebar...

Page 18: ...e fuel supply 8 2 Starting Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient...

Page 19: ...he throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Your child should switch off the engine if he or she...

Page 20: ...be damaged by incorrect procedure when parking Significant damage may be caused if the vehicle rolls away or falls over The components for parking the vehicle are designed only for the weight of the...

Page 21: ...in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contac...

Page 22: ...ket and chain guide p 43 Check the chain tension p 42 Lubricate all moving parts e g hand levers chain and check for smooth operation Change the hydraulic clutch fluid p 47 Check the fluid level of th...

Page 23: ...ithout sharp bends and correct adjustment Clean the air filter and air filter box p 38 Change the glass fiber yarn filling of the main silencer p 39 Check the screws and nuts for tightness Check set t...

Page 24: ...the rear wheel suspension and not to the vehicle speed The high speed setting for example has an effect on the landing after a jump the rear wheel suspension compresses more quickly The low speed sett...

Page 25: ...r of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 1 5 turns Standard 1 turn Sport 0 5 turns Info Turn clockwise to increase damping turn counterclock...

Page 26: ...ent Info The static sag is the difference between measurements and Check the static sag Static sag 30 mm 1 18 in If the static sag is less or more than the specified value Adjust the spring preload of...

Page 27: ...Info The spring preload is the difference between the relaxed spring length and the tensioned spring length Depending on the static sag and or the riding sag it may be necessary to increase or decreas...

Page 28: ...djusting screw clockwise all the way Info Adjusting screw is located at the top end of the right fork leg and is labeled with COM Turn counterclockwise by the number of clicks corresponding to the for...

Page 29: ...erial fatigue and the handlebar can break Always replace handle bar 601951 11 Remove the screws Take off the handlebar clamps Remove the handlebar and lay it to one side Info Protect the motorcycle an...

Page 30: ...d Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface 402581 10 Remove the motorcycle from the lift stand Remove the lift stand To p...

Page 31: ...ays keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 84 Press the d...

Page 32: ...ine loosely to the side S00870 10 Loosen screws Remove the left fork leg Loosen screws Remove the right fork leg 11 8 Installing the fork legs Warning Danger of accidents Modifications to the suspensi...

Page 33: ...e with a lift stand p 28 Remove the front wheel p 58 Remove the fork legs p 30 Remove the start number plate p 34 Dismount the front fender p 35 K00210 10 Main work Remove fuel tank breather Remove nu...

Page 34: ...r steering head seal is correctly positioned Push on protective ring H00152 10 Position the upper triple clamp with the handlebar Mount nut but do not tighten it yet H00153 10 Position the fork legs I...

Page 35: ...he front wheel p 58 Check play of steering head bearing p 33 Remove the motorcycle from the lift stand p 28 11 11 Checking play of steering head bearing Warning Danger of accidents Unstable vehicle ha...

Page 36: ...work Remove fuel tank breather Loosen screws Loosen screw Loosen and retighten nut Guideline Nut steering stem M20x1 5 10 Nm 7 4 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to...

Page 37: ...ew Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 16 Dismounting the front fender 602674 10 Remove screws Remove the front fender 11 17 Installing the front fender H00141 10 Position the fe...

Page 38: ...0121 11 Main work Push splash protector to the side and position the shock absorber Mount and tighten screw Guideline Screw top shock absorber M10 45 Nm 33 2 lbf ft Loctite 243 Mount and tighten screw...

Page 39: ...osed of as stipulated in applicable regulations Preparatory work Remove the seat p 36 H00158 10 Main work Unhook the air filter holder and swing it to the side Remove the air filter with the air filte...

Page 40: ...y Air filter cleaner p 83 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 83 Clean the air filter box Check...

Page 41: ...h the toothed washers Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Finishing work Install the main silencer p 38 11 28 Dismounting the fuel tank Danger Fire hazard Fuel is highly flammable N...

Page 42: ...tank expands when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the ski...

Page 43: ...arning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or gr...

Page 44: ...k Press the chain upward at the end of the chain sliding piece and determine chain tension Info The upper part of chain must be taut Chain wear is not always even so you should repeat this measurement...

Page 45: ...ycle with a lift stand p 28 400227 01 Main work Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the drive set Info The engine sprocket rea...

Page 46: ...below the chain sliding piece Change the chain sliding piece Check that the chain sliding piece is firmly seated If the chain sliding piece is loose Tighten the chain sliding piece Guideline Remainin...

Page 47: ...the swingarm is not authorized by KTM 11 37 Checking the routing of the throttle cable Preparatory work Remove the seat p 36 Turn the knurled screw on the fuel tap all the way clockwise Dismount the...

Page 48: ...tment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 11 41 Checking the fluid level of the hydraulic clutch Info The fluid level r...

Page 49: ...ontal position Remove screws Remove cover with membrane H00109 10 Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 81 On the slave cylin...

Page 50: ...ween the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar The range of adjustment is limited Turn th...

Page 51: ...silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake...

Page 52: ...ake linings p 50 H00110 10 Main work Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Correct the brake fluid level Guideline B...

Page 53: ...purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed...

Page 54: ...oved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are u...

Page 55: ...can fail due to overheating Adjust the free travel on foot brake lever according to specifications H00161 10 Detach the spring Loosen nut Turn push rod until clearance is created Guideline Free travel...

Page 56: ...uid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Check the brake system and do not continue riding Your authorized KTM workshop will be glad to...

Page 57: ...ess 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings p 55 Check the brake linings for damage and cracking If damage or wear is encountered Change the rear bra...

Page 58: ...imension brake fluid level below top edge of container 10 mm 0 39 in Brake fluid DOT 4 DOT 5 1 p 81 Position the membrane and the cover with the washer Mount and tighten the screws Info Clean up overf...

Page 59: ...he brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license Th...

Page 60: ...ced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary 601957 11 Check the wheel bearing for...

Page 61: ...ge by covering them Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the swingarm Info Do not operate the foot brake lever when the rear wheel is removed Always lay the whe...

Page 62: ...uts run in objects and other damage If the tires exhibit cuts run in objects or other damage Change the tires Check the depth of the tread Info Note local national regulations concerning the minimum t...

Page 63: ...they can break due to local overload Check the spoke tension regularly especially on a new motorcycle 400694 01 Briefly strike each spoke with the blade of a screwdriver Info The frequency of the ton...

Page 64: ...case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the skin eyes or clothing If contact...

Page 65: ...10 mm 0 39 in If the coolant level does not meet specifications Correct the coolant level Coolant p 81 Mount the radiator cap 14 4 Draining the coolant Warning Danger of scalding During motorcycle ope...

Page 66: ...screw is tightened Position the motorcycle upright Add coolant to level Guideline Distance above the radiator fins 10 mm 0 39 in Coolant 0 55 l 0 58 qt Coolant p 81 0 0 A A 0 0 B B 400677 11 Move the...

Page 67: ...system Start the engine and let it idle Move the handlebar to and fro over the entire steer ing range The idle speed should not change If the idle speed changes Adjust the play in the throttle cable p...

Page 68: ...make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an effective exhaust extraction system Adjust the idle speed with the adjusting screw Guidel...

Page 69: ...th water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been con...

Page 70: ...M6 6 Nm 4 4 lbf ft 16 2 Changing the gear oil 400721 01 Drain the gear oil p 68 400722 01 Fill up with gear oil p 69 16 3 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get...

Page 71: ...of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the...

Page 72: ...nd inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enclosed space without an...

Page 73: ...Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle water...

Page 74: ...f the new season 401058 01 When refueling the last time before taking the motorcycle out of service add fuel additive Fuel additive p 83 Fill up with fuel p 19 Clean the motorcycle p 71 Change the gea...

Page 75: ...Check the spark plug connector Engine does not speed up Carburetor running over because float needle dirty or worn Check set the carburetor components Loose carburetor jets Check set the carburetor c...

Page 76: ...ad or cylinder head gas ket Bent radiator hose Change the radiator hose Incorrect ignition point due to loose stator Adjust the ignition White smoke emission steam in exhaust gas Damaged cylinder head...

Page 77: ...e gap 0 60 mm 0 0236 in Cooling Water cooled Starting aid Kickstarter 20 2 Engine tightening torques Nut exhaust control diaphragm M5 4 Nm 3 lbf ft Screw clutch line holder M5 5 Nm 3 7 lbf ft Screw di...

Page 78: ...3 lbf ft Nuts cylinder base M8 20 Nm 14 8 lbf ft Screw kickstarter M8 25 Nm 18 4 lbf ft Loctite 243 Stud cylinder base left section of the engine case M8 Tightening sequence screw in until it projects...

Page 79: ...100810 01 M FT ASL Above sea level TEMP Temperature ASO Idle air adjusting screw open rotations IJ Idling jet NDL Jet needle POS Needle position from above MJ Main jet The carburetor tuning depends on...

Page 80: ...17 1 lb in Spring length with preload spacer s 377 5 mm 14 862 in Fork length 735 mm 28 94 in Fork oil per fork leg 240 10 ml 8 11 0 34 fl oz Fork oil SAE 4 48601166S1 p 81 20 6 Shock absorber Shock...

Page 81: ...Brake disc diameters Front 198 mm 7 8 in Rear 160 mm 6 3 in Brake discs wear limits Front 2 5 mm 0 098 in Rear 2 5 mm 0 098 in Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Seco...

Page 82: ...ew bottom triple clamp M8 15 Nm 11 1 lbf ft Screw brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw engine bracket M8 30 Nm 22 1 lbf ft Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw rear sprocke...

Page 83: ...49 F anti corrosion antifreeze distilled water Recommended supplier Motorex COOLANT M3 0 Engine oil 15W 50 Standard classification JASO T903 MA p 85 SAE p 85 15W 50 Guideline Use only engine oils that...

Page 84: ...RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel co...

Page 85: ...ended supplier SKF LGHB 2 Long life grease Recommended supplier Motorex Bike Grease 2000 Motorcycle cleaner Recommended supplier Motorex Moto Clean Off road chain spray Recommended supplier Motorex Ch...

Page 86: ...22 AUXILIARY SUBSTANCES 84 Universal oil spray Recommended supplier Motorex Joker 440 Synthetic...

Page 87: ...In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the S...

Page 88: ...cking 42 Chassis number 10 Choke 12 Cleaning 71 Clutch fluid level checking 46 fluid level correcting 46 fluid changing 47 Clutch lever 11 basic position adjusting 46 Compression damping fork adjustin...

Page 89: ...oving 59 Rebound damping fork adjusting 26 shock absorber adjusting 23 Riding sag adjusting 25 Rubber grip checking 45 securing 46 S Safe operation 5 Seat mounting 36 removing 36 Service 7 Service sch...

Page 90: ...INDEX 88 U Use definition 5 V View of vehicle front left 8 rear right 9 W Warranty 7 Work rules 6...

Page 91: ...3213328en 3213328en 06 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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KTM 65 SX 1999, Owner'S Manual

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Summary of Contents for 65 SX 1999

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